Form structure

ABSTRACT

This invention is a form structure of lightweight construction so as to be readily movable during various stages of construction while providing a rigid structure operable for construction of concrete walls without warpage. More particularly, this invention is a form structure including (1) a main body of vinyl foam core having exposed surfaces covered by layers of fiberglass material and the concrete contacting surface provided with a Black Gel coat of polyester resin, (2) upright edges provided with interlocking joint members whereupon adjacent form structures can be secured to each other through the use of latch and hook assemblies; and (3) a plurality of horizontally extended ty-hole assemblies are provided for interconnecting adjacent, cooperating front and back form structures in a spaced relationship for pouring concrete or like materials therebetween.

United States Patent [72] Inventor Charles D. Mattingly Wichita, Runs.

[21 Appl. No 758,255

[22] Filed Sept. 9, 1968 [45] Patented July 13, 1971 [73] Assignee Mattingly, Inc. Wichita, Kans.

54 FORM STRUCTURE 4Cla1ms,7DrawingFigs.

52 use: 249/1, 52/6l5,25/l18R,249/l92 51] lnt.Cl E02bl/00 so FieldoiSeard: 249/1,2,

10,18, 33,40,44,47,118,119,134, 155,156, 160,168,187,l88,189,190,192, DIG. 3; 25/1 18, 131 P, 131 C1, 131 D, 131 T; 52/615, 593, 309,

[56] References Cited UNITED STATES PATENTS 1,880,153 9/1932 Rosenzweig .1 52/615 X Primary Examiner-J. Spencer Overholser Assistant ExaminerDeWalden W. Jones Attorney-Phillip A. Rein ABSTRACT: This invention is a form structure of lightweight construction so as to be readily movable during various stages of construction while providing a rigid structure operable for construction of concrete walls without warpage. More particularly, this invention is a form structure including (1) a main body of vinyl foam core having exposed surfaces covered by layers of fiberglass material and the concrete contacting surface provided with a Black Gel coat of polyester resin, (2) upright edges provided with interlocking joint members whereupon adjacent form structures can be secured to each other through the use of latch and hook assemblies; and (3) a plurality of horizontally extended ty-hole assemblies are provided for interconnecting adjacent, cooperating front and back form structures in a spaced relationship for pouring concrete or like materials therebetween.

PATENTED JUL 1 3 I97:

IMVEN'H R CHARLES D. MATTINGLY AT TORNE'Y FORM STRUCTURE In the prior art devices, it is very common to use plywood or metal forms when using the same for poured concrete and they are fairly suitable for flat surfaces even though they do not produce the smooth, nongrainy finishes on exposed concrete surfaces which is achieved with the form structures of this invention. The use of plywood forms generally leaves ragged edges and parting lines which require sandblasting or other costly finishing operations. Also, the metal forms are generally bulky to handle and must be of heavy guage steel if the same is to achieve an end product wall or the like not having wavy portions therein. Additionally, the prior art metal forms are subject to warpage; rust which is undesirable due to the high replacement cost; buckling and fail to produce a smooth continuous surface; and are dangerous to handle due to weight. There are certain plastic laminated forms available on the market but they are generally unacceptable due to excessive wear of the plastic surface of the form which occurs during separation of the hardened concrete from the form. Additionally, the plastic material of the prior art forms whether of the polyester-styrene-type of mixed resin or the epoxy resin type is substantially corroded and eroded at its parting surface by the concrete.

In one preferred embodiment of this invention, a complete set of interconnected inside and outside form structures are operable to produce a contoured, ultimate design swimming pool structure. First, a large area is excavated and the form structures are set therein interconnected as by ty-cone assemblies whereupon the area therebetween is filled with fresh concrete allowed to flow downwardly and laterally of the lower surface of the inside form structures whereupon the floor area is easily finished therebetween in one complete, unique operation. The inside and outside form structures are substantially identical in structure varying only by the contour and design in order to achieve the final product. Each form structure is provided with a support assembly having upright joint edge structures secured to a main body adapted to lockingly engage an abutting form structure and secured thereto in a clamped relationship by a plurality of spaced latch and hook assemblies. The support assembly further includes an upper horizontally extended top edge assembly; a lower bottom edge assembly; and a plurality of spaced horizontal tyhole assemblies extended between and parallel to the edge assemblies. The main body is constructed of a lightweight vinyl foam core having on one side a form front wall assembly adapted to receive the poured concrete thereagainst and on the opposite side, a form outside wall assembly. The form front assembly includes in this order from against the vinyl form core and moving outward thereof, two separate layers of l /ounce weight fiberglass matt material; a ounce weight fiberglass cloth material; these layers are bonded to adjacent layers through a polyester resin material; a three quarter ounce weight fiberglass matt material; and a final outer coat of Black Gel Coat Polyester Resin, which provides for a smooth, hard outer surface adapted to receive the concrete material thereagainst to achieve a smooth, final finish. The form outside wall assembly includes a layer of llounce weight fiberglass matt material mounted against the vinyl foam core and bonded thereto as by resin and an outer surface of a fiberglass woven roving bonded thereto as bya polyester resin. Adjacent each of the joint edge structures on the outside wall assembly is an additional four inch strip of lkounce fiberglass matt so as to provide rigidity and a positive bonding with the preferably aluminum upright joint edge structures. Each horizontal ty-hole assembly includes an elongated wood member extended between the joint edge structures. This wood member also provides an anchoring area for attaching respective ones of the latch and hook assemblies for interconnecting adjacent form structures. At spaced intervals along the wood member are openings having a cylindrical element securely mounted therein adapted to receive a lag bolt for at- -tarhinu adiart nt nnPs of the inside and outside fonns. 'Addi Lil tionally, the opposite surfaces of the wood members of the horizontal ty-hole assemblies are provided with aluminum strips for anchoring purposes. The top horizontal ty-hole assembly is provided with a main wood member having near its lower edge spaced holes to receive the cylindrical elements therein. Additionally, the top exposed edge of the main body is covered by an elongated edging member of U-shape in transverse cross section secured as by a plurality of nails to provide protection for the same against the elements and wear. The bottom horizontal ty-hole assembly is provided with an elongated wood member extended the length thereof having an outer arcuate surface so as to be readily releasable from the concrete material poured thereabout.

One object of this invention is to provide ,a form structure overcoming the above-mentioned disadvantages of the prior art structures.

A further object of this invention is to provide form structures including a main body; upright rigid and interlocking joint edging structures for connecting adjacent ones thereof; a plurality of latch and hook assemblies to readily and easily interconnect adjacent form structures; and a plurality of spaced horizontal ty-hole assemblies providing rigid means for releasably connecting spaced adjacent ones of the form structures in a most efficient and effective manner.

One further object of thisinvention is to provide a form structure including a main vinyl foam core body; an outer form front wall assembly having a plurality of layers of fiberglass material interconnected as by polyester resin and an outer wear surface of Black Gel Coat Polyester Resin; and an outside form wall assembly having a fiberglass matt material mounted thereon and anchored through resin to provide a rigid overall structure.

Still, one other object of this invention is to provide .a form structure (I) that is substantially rigid in construction so as to withstand the tremendous buckling and warpage forces thereagainst during the concrete pouring operations; (2) that is lightweight in structure so as to be readily movable and easily handled by two workers without the use of heavy construction crane equipment; and (3) which is substantially maintenance free usable over and over without noticable wear thereof.

Another object of this invention is to provide a form structure having a main body of lightweight core material covered on opposite sides by bonded layers of a high strength material such as fiberglass, Dynel and polypropylene to achieve a durable, lightweight, rigid and relatively inexpensive structure.

Various other objects, advantages, and features of the invention will become apparent to those skilled in the art from the following discussion, taken in conjunction with the accompanying drawings, in which:

FIG. 1 is a perspective view of a swimming pool under construction utilizing the inside and outside form structures of this invention;

FIG. 2 is a fragmentary elevational view of an .inside form structure of this invention;

FIG. 3 is an enlarged sectional view taken along line 3-3 in FIG. 1;

FIG. 4 is an enlarged sectional view taken along line 4-4 in FIG. 2;

FIG. 5 is an enlarged fragmentary sectional view taken along line 5-5 in FIG. 2;

FIG. 6 is an enlarged fragmentary sectional view of a top horizontal ty-hole assembly of the form structure of this invention; and

FIG. 7 is a viewsimilar to FIG. 6 illustrating abottom edge assembly of the vform structure of this invention.

The following is .a discussion and description .ofpreferred specific embodiments of the new form structure of this invention, such being made with reference to the drawings, whereupon the same reference numerals are used to indicate. the sameor similar parts and/or structure..It is. to be understood that such discussion and description is not to unduly limit the -scooe-'of the invention.

Referring to the drawings in detail and in particular FIGS. 1 and 2, a contoured swimming pool under construction is indicated generally at wherein the same is being constructed as by the use of inside and outside forms 12 and 14, respectively, which forms the subject matter of this invention.

As shown in FIG. 3, it is seen that during construction a large area is excavated whereupon the outside forms 14 are mounted in an upright position and interconnected to adjacent outside forms whereupon the inside forms 12 are connected to the outside forms 14 as by ty-cone assemblies 16 which will be explained. As best shown in FIG. 2, it is seen that the inside form structures 12 are interconnected to adjacent ones thereof as by latch and hook assemblies 18 at spaced intervals to provide a rigid interconnected structure as will become obvious. As the inside form structures 12 and the out side form structures 14 are substantially identical varying only in specific shape and contour, the detailed discussion of one such form structure generally applies to the other.

A cross section of the inside form structure 12 (FIG. 4) includes a main body 19 constructed of a vinyl foam core material indicated at 21; a contact form wall assembly 23; an outside form wall assembly 25; upright joint members 26 secured to upright exposed edges of the main body 19; a plurality of horizontally extended ty-hole assemblies 27; an upper edge member or ty-hole assembly 28; a bottom edge member assembly 30; and a plurality of the latch and hook assemblies 18 having a latch member 32 secured to one upright edge and a hook member 33 secured to the opposite upright edge thereof so as to be connectable to adjacent ones of similarly constructed inside form structures 12.

The main body 19 is preferably constructed of the vinyl foam core material known for its lightweight qualities such as plastic foam sandwich materials like Plyfoam manufactured by Potter Marine, Plainview, New York. However, it has been proven that a core structure of ordinary white pine or balsa can be used but a plastic foam is desirable for the weight characteristics. The main function of the main body 19 is to stabilize and stiffen the outer facings which have high tensile strength, as will become obvious.

The contact form wall assembly 23 comprises a plurality of layers bonded to each other against the vinyl foam core 21 including two layers 35 and 37 of a l rounce sq. ft. weight matt fiberglass; a 10 ounce sq. yd. weight, 14 mils thick layer 38 of treated fiberglass cloth material; a layer 39 of three-quarter ounce sq. ft. weight matt fiberglass material; and an outer durable coat 41 being of a Black Gel Coat Polyester Resin. It is obvious that the various layers of fiberglass material are all interconnected and built up in a step by step process through the use of the polyester resin which is applied by brush or spray to each layer of fiberglass material.

The outside form wall assembly 25 is constructed of a 1%ounce sq. ft. weight matt fiberglass material layer indicated at 43 and secured to the main body 19 as by a resin material. Additionally, the outer surface is provided with a layer 44 of woven roving being of a heavy weave fiberglass of 22 ounce sq. yd. weight and 50 mils thick. It is obvious that the layers 43 and 44 are interconnected to themselves and adjacent portions of the form structure 12 by the resin material.

Although fiberglass in the matt, cloth, and woven state has proven most satisfactory, it is noted that dynel could be used instead having a lower specific gravity, greater flexural strength, and excellent for resin impregnation. Also, a polypropylene fabric may be used having greater abrasion resistance, flexural strength, and tensile strength compared to both fiberglass and dynel.

Each upright joint member 26 is preferably constructed of an aluminum material for rigidity plus lightweight characteristics. Each joint member 26 is provided with an upright backwall integral sidewalls 47, and an irregularly shaped front wall 48. More particularly, the front wall 48 is provided with an outwardly extended projection 49 in one-half section and a reverse concave similarly shaped surface indicated at 51 in the other half section. The maximum width of the projection 49 at the concave surface 51 is preferably one-half the depth thereof to achieve the proper and efficient locking features. Thereupon it is seen that the outer configuration of the front wall 48 results in adjacent ones of such shaped joint members 26 being placed into mating relationship to provide a rigid structure for lateral stability. It is seen that each of the joint members 26 extends on opposite upright sides of the form structures 12 and 14 so as to provide an easy means of connection.

As best shown in FIG. 5, it is seen that each of the horizontal ty-hole assemblies 27 is substantially identical so only one need be described in detail. More particularly, each horizontal ty-hole assembly 27 includes an elongated support body 55 preferably constructed of a wood material with the outer upright sides covered with an aluminum striping material indicated at 56 for rigidity on applying nails thereto which is necessary and advisable during the construction process. Each support body 55 is provided with a plurality of spaced holes 58 each adapted to receive a cylindrical segment or element 59 in a snug, anchored relationship. The cylindrical elements 59 are preferably constructed of a heavy duty metalic material for wear resistance necessary for assembly and disassembly of the adjacent form structure 12, 14 as will become obvious. The outside form wall assembly 25 that covers the area of the spaced holes 58 are provided with a washer or wear plate 61 to receive the lag bolts thereagainst. It is seen that the ty-hole assemblies 27 have the spaced holes 58 in vertical alignment structures for interconnecting the same as will become obvious. Additionally, it is seen that the thickness of the support body 55 is substantially equal to that of the vinyl foam core 21 so that the outer surfaces thereof are also covered with the contact form wall assembly 23 and the outside form wall assembly 25.

As shown in FIG. 6, only the outside form structure 14 includes the upper ty-hole assembly 28 having an elongated main wood support member 62 with its lowermost sides connected to the adjacent vinyl foam core 21 and having a plurality of spaced holes 63 therein vertically aligned with similar ones on the horizontal ty-hole assemblies 27. The upper ex posed surface of the support member 62 is enclosed by an edging member 65 of substantially U-shape in transverse cross section. The edging member 65 is preferably constructed of an aluminum material extended over the entire upper surface of the support member 62 and also the covering of the contact form wall assembly 23 and the outside form wall assembly 25 and secured thereto as by a plurality of nail members 66. The holes 63 are also provided with the cylindrical elements 59 therein so as to receive lag bolts therethrough. Additionally, the holes 63 are located near the lower edge of the support member 62 so that the ty-cone assembly 16 connected thereto will be below the upper surface so as to present a solid structure when the inside and outside form structures 12 and 14 are removed.

As shown in FIG. 7, only the outside form structure 14 includes the bottom edge assembly-30 provided with an arcuate contour indicated at 68 and is constructed with an irregular shaped elongated base member 69 preferably constructed of a wood material. The upper portion of the base member 69 is provided with irregular surfaces 71 adapted to contact and bond to the vinyl foam core 21. The outer lower surface of the base member 69 is provided with a curve so that the same is easily removable from the concrete material as required during the finishing operations and removing the form structures 14 therefrom. It is seen that the bottom edge on the inside form structure 12 extends upright to provide a control surface for finishing a bottom area 75 of the swimming pool 10.

In the construction of the form structures 12 and 14, a master mold or jig is provided wherein the same is waxed and coated with a vinyl parting film. The layer or coat 41 of Black Gel-Coat Polyester Resin is applied to the master mold and the layer 39 of three-quarter ounce matt laid thereon. Next, the respective layers 38, 37, and 35 of 10 ounce fiberglass cloth and l kounce fiberglass matt are mounted thereon, all

separated and interconnected by coats of polyester resin. The joint members 26 and necessary ty-hole assemblies 27 and 28 are placed on proper anchors of the master jig. The foam core 21 is placed between the ty-hole assemblies 27, 28 and the joint members 26.

The outside form wall assembly 25 is built up and strengthened by applying a 4 inch strip 77 of 1% ounce fiberglass layer over the joint members 26 then adding the complete covering of layers 413 and 44 of matt and woven roving, respectively. All are separated and bonded together by the polyester resin. After setting and curing the latch and hook assemblies 18 are mounted thereon.

On construction of the outside from structure 14, the top edge assembly 28 and the bottom edge assembly 30 are mounted in the master jig for integral formation therewith. (FIGS. 6 and 7) An upper section 79 of the inside form structure 12 includes all of the fiberglass layers in the contact wall assembly 23 and the outside wall assembly 25 without the use of the foam core 21. This can be achieved due to smaller load applied in this area by the poured concrete. These layers are readily contoured shown in 81 to achieve an integral deck construction not requiring coping blocks.

lt is obvious that the outside form structures 12 are similarly constructed only varying in contour needed as can be seen by being upright and having an upper lateral section 83 operable to provide sufficient strength plus forming an integral area about the swimming pool structure 10. The curved areas of the inside and outside forms 12 and 14, respectively, adds considerable strength to prevent flexing about vertical planes.

It is seen in the form structures 12 and 14 of this invention, that very sturdy, durable, lightweight and reliable forrris are constructed for placing concrete material or the like therebetween. Additionally, the upright joint members 26 of the form structures 12 and 14 are provided with interlocking features to provide substantial lateral stability in combination with the latch and hook assemblies 18. As shown in FIGS. 3 and 5, the ty-cone assemblies 16 are substantially conventional having a main wire body 85 with each opposite end each secured to a cone member 87 having a hole 88 therethrough. Lag bolts 91 are inserted through respective ones of the holes 58 in the horizontal ty-hole assemblies 27 and the top ty-hole assembly 28 and rotatable so as to be secured and anchored in a rigid manner to the main wire body 85 of the tycone assembly 16. This provides for the positive spacing and substantial rigidity of the inside and outside forms 12 and 14, as shown in FIG. 3. Additionally, after pouring the concrete material indicated at 93 and the same has become hardened, the inside and outside forms 12 and 14 may be readily disassembled on removing the lag bolts 91 whereupon the cone members 87 may be removed. Thereafter, the conical holes can be easily filled with a plaster material to provide a neat appearing pool structure.

lt is seen that the form structures of this invention arepro vided with a main vinyl foam core having tremendous strength with the outer skins and a hard, smooth outer surface so that the finished product of the swimming pool needs very little if any touch-up to achieve the final structure. Also, the lightweight of the overall form structure permits the same to be readily carried and maneuvered by one and not more than two persons for attachment to an adjacent one of the form structures through the latch and hook assemblies. Additionally, the lightweight feature of the form structures permits the same to be readily transported in conventional trailer structures to move from one job site to another.

As will be apparent from the foregoing description of the applicant's invention, relatively inexpensive means have been provided preferably for construction of a swimming pool structure, namely, form structures that are lightweight, economical to manufacture, and substantially maintenance free, lasting a lifetime with proper care as not being affected by the elements and corrosion factors. Additionally, it is seen that the construction of the form structures is such that the.

that this description is intended to illustrate and not to limitv the scope of the invention, which is defined by the following claims.

1 claim:

1. A form structure for use in retaining concrete material or the like, comprising;

a.'a main body constructed of a lightweight core material,

b. spaced upright end joint members secured to opposite. upright ends of said main body, and upper and lower edge; members secured to respective upper and lower edges of said main body,

c. means mounted adjacent said upright end joint members for securing to other ones of said form structures, and

d. a contact form wall assembly and an outside form wall assembly secured to respective opposite sides of said main. body, said upright end joint members, and said upper and; lower edge members to provide strength thereto through films created thereby and said contact form wall assembly. having an outer polyester resin surface thereonproviding a hard, smooth, coating over said main body to achieve a.-

smooth surface on the finished concrete product.

c. said upright end joint members having an outer irregular; configuration with an outer contoured projection anda; reversely contoured concave section so that adjacent; ones of said form structures can be interconnected to: each other so as to provide lateralstability by contacting; surfaces of said projections and said concave sections, and said securing means including a plurality of spaced latch: and hook members secured to opposite upright-edges of said main body adjacent and upright end joint members. so as to be readily connectable to adjacent ones of said} form structures so as to achieve any desiredshape therefrom.

2. A form structure as described in claim I, wherein;

. said contact form wall assembly including a plurality-of; layers of fiberglass material first mounted against said. upright end joint members, said upper and lower edge: members, and said main body and secured thereto and to each other by a resin material,

b. said polyester resin being a black gel coat of polyester resin against the outermost surface of said fiberglass, layers to provide a water-repellent outer surfaceachieving a smoothlike end product with the concrete material; with substantial wear resistant qualities,

c. said main body constructed of sheets of vinyl foam core-1 material, and

d. a plurality of horizontal ty-hole assemblies divides respec.- tive ones of said sheets whereupon said contact form wall; assembly and said outside form wall assembly binds saidhorizontal ty-hole assemblies and said sheets, upright end-1 joint members, upper edge member, and lower edge:

member into a completely rigid structure. 3. A form structure as described in claim 1, wherein: a. said contact form wall assembly including mounted against said main body in this order, two layers of llounce per sq. ft. matt fiberglass materialv secured thereto as by a resin material; a 10 ounce per sq. yard. treated fiberglass cloth material mounted thereagainst and secured thereto by a resin material; a three-quarter, ounce per sq. ft. matt fiberglass material; and said polyester resin being a black gel coat polyester resin.

mounted against the outer surface of saidthree-quarter substantial rigidity being a corrosion resistant and lightweight form structure. 

1. A form structure for use in retaining concrete material or the like, comprising; a. a main body constructed of a lightweight core material, b. spaced upright end joint members secured to opposite upright ends of said main body, and upper and lower edge members secured to respective upper and lower edges of said main body, c. means mounted adjacent said upright end joint members for securing to other ones of said form structures, and d. a contact form wall assembly and an outside form wall assembly secured to respective opposite sides of said main body, said upright end joint members, and said upper and lower edge members to provide strength thereto through films created thereby and said contact form wall assembly having an outer polyester resin surface thereon providing a hard, smooth, coating over said main body to achieve a smooth surface on the finished concrete product. e. said upright end joint members having an outer iRregular configuration with an outer contoured projection and a reversely contoured concave section so that adjacent ones of said form structures can be interconnected to each other so as to provide lateral stability by contacting surfaces of said projections and said concave sections, and f. said securing means including a plurality of spaced latch and hook members secured to opposite upright edges of said main body adjacent and upright end joint members so as to be readily connectable to adjacent ones of said form structures so as to achieve any desired shape therefrom.
 2. A form structure as described in claim 1, wherein; a. said contact form wall assembly including a plurality of layers of fiberglass material first mounted against said upright end joint members, said upper and lower edge members, and said main body and secured thereto and to each other by a resin material, b. said polyester resin being a black gel coat of polyester resin against the outermost surface of said fiberglass layers to provide a water-repellent outer surface achieving a smoothlike end product with the concrete material with substantial wear resistant qualities, c. said main body constructed of sheets of vinyl foam core material, and d. a plurality of horizontal ty-hole assemblies divides respective ones of said sheets whereupon said contact form wall assembly and said outside form wall assembly binds said horizontal ty-hole assemblies and said sheets, upright end joint members, upper edge member, and lower edge member into a completely rigid structure.
 3. A form structure as described in claim 1, wherein: a. said contact form wall assembly including mounted against said main body in this order, two layers of 1 1/2 ounce per sq. ft. matt fiberglass material secured thereto as by a resin material; a 10 ounce per sq. yard treated fiberglass cloth material mounted thereagainst and secured thereto by a resin material; a three-quarter ounce per sq. ft. matt fiberglass material; and said polyester resin being a black gel coat polyester resin mounted against the outer surface of said three-quarter ounce matt fiberglass material to present an overall rigid structure.
 4. A form structure as described in claim 1, wherein: a. said outside form wall assembly including a first 1 1/2 ounce per sq. ft. matt fiberglass strip against said upright end joint member, said upper and lower edge members, and said main body, and b. a 22 ounce per sq. yard woven roving fiberglass material is placed thereagainst and secured thereto as by a resin material to provide an overall sealed structure having substantial rigidity being a corrosion resistant and lightweight form structure. 